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On-Line Valve PM Process Flow Diagram

1. The document describes the process flow for online valve preventative maintenance (PM). 2. It involves checking valves to see if they have been previously maintained, flushing valves if needed, lubricating valves, and flushing and sealing valves if passing or leaking. 3. The process includes steps for lubrication only, flushing and lubrication, or flushing and sealing depending on the valve's condition and maintenance history. A daily summary report is also prepared.

Uploaded by

Syahroslizam Suhaimi
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
281 views

On-Line Valve PM Process Flow Diagram

1. The document describes the process flow for online valve preventative maintenance (PM). 2. It involves checking valves to see if they have been previously maintained, flushing valves if needed, lubricating valves, and flushing and sealing valves if passing or leaking. 3. The process includes steps for lubrication only, flushing and lubrication, or flushing and sealing depending on the valve's condition and maintenance history. A daily summary report is also prepared.

Uploaded by

Syahroslizam Suhaimi
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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On-Line Valve PM PROCESS FLOW DIAGRAM

NO

START

YES
VALVE PASSING?

YES
VALVE DONE WITH On-Line Valve PM PRODUCTS BEFORE?

NO
VALVE FLUSHED MORE THAN 6 MONTHS AGO?

FLUSH VALVE WITH ESS VK1

YES
INJECT ESS HV OR ESS VMHV VALVE SEALANT

NO
FLUSH VALVE WITH ESS VK1

YES
LUBRICATE VALVE WITH ESS 600 INJECT ESS HV REPAIR SEALANT VALVE PASSING?

NO YES
PREPARE REPORT VALVE BEYOND SEALING, MECHANICAL REPAIR REQUIRED END PREPARE REPORT VALVE PASSING? PREPARE REPORT

NO
END

END

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On-Line Valve Preventive Maintenance (PM) WORK PROCEDURE 1. Check and identify details of valve and if the valve was done with On-Line Valve PM PROCESS and PRODUCTS before. 2. Flushing process is required for valves under the following scenarios; a. Jammed unable or difficult to turn the valve. b. Leaking Leakage of product through injection fitting or valve bleed fitting. c. Passing Product passed through valve seat at close position. d. Valve was flushed with On-Line Valve PM PROCESS and PRODUCT for more than 6 months ago. 3. If valve NOT passing / leaking / jammed, and was flushed less than 6 months ago, proceed with Lubrication steps below. 4. If valve NOT passing / leaking but jammed or was flushed more than 6 months ago, proceed with Flushing and Lubrication steps. 5. If valve passing / leaking, then follow the procedure for Flushing & Sealing. LUBRICATION 1. Check the valve lubricant injection fittings and replace any standard button head fittings to SS Vent Cap fittings for safe product injection whenever necessary and possible To change fitting valve shutdown is required. 2. Inject ESS 600 Lubricant (amount according to valve size) to lubricate and preserve the valve from corrosion. FLUSHING AND LUBRICATION 1. Check the valve fittings and replace any standard button head fittings to SS Vent Cap fittings for safe product injection whenever necessary and possible To change fitting valve shutdown is required. 2. Inject ESS VK1 Flush to clean and remove any rust or debris in the valve using the ESS FM-II Flush Master Pump. 3. Give time for flush to soak and clean the valve internals cavity and let it dry for a minimum of 30 minutes. 4. Inject ESS 600 Lubricant (amount according to valve size) to lubricate and preserve the valve from corrosion. FLUSHING AND SEALING 1. Check the valve fittings and replace any standard button head fittings to SS Vent Cap fittings for safe product injection whenever necessary and possible To change fitting valve shutdown is required. 2. Inject ESS VK1 Flush to clean and remove any rust or debris in the valve using the ESS FM-II Flush Master Pump. 3. Give time for flush to soak and clean the valve internals cavity and let it dry for a minimum of 30 minutes. 4. Inject the ESS HV Super Sealant to seal the passing valve using the ESS 751 Valve Master Pump. More than 95% of the valve should be sealed at this stage unless the ball or gate or plug is badly worn out. 5. In the event of the valve is still passing, inject ESS VR Valve Repair Sealant. This is a final attempt to seal the damaged valve on-line. If the valve is still passing, then this valve should be removed from the line for mechanical repair during the next shutdown opportunity.

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NO.:.. Job No: Client: Contract No:


Item No.: Tag No Line No

DAILY VALVE SERVICE SUMMARY REPORT Job Description: Service Supervisor: Location: Service Technician: Order No: Client Representative:
Size Class Brand Model No. Serial No. Flush (lbs) Lubricants (lbs) Sealant V.tag Ftg-C/out Detail of Existing Fittings Qty Size Type Action

TOTAL
COMMENTS

Type of Fittings Note: Action

Next 24hrs activities / Remarks Status of Equipment Breakdown Type of equipment Description of Breakdown

Service Supervisor Client Representative

Signed / Chop Signed / Chop

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